Needle with multi-bevel tip geometry

ABSTRACT

A multi-beveled needle point geometry for hypodermic needles such as pen needles. A proximal bevel is formed at a first angle of inclination, a pair of intermediate bevels at a second angle of inclination, and a pair of distal bevels at a third angle of inclination and differing angles of rotation. The second angle of inclination is substantially different than the first angle of inclination to define a marked apex at the intersections between the proximal bevel and the intermediate bevels. At least one smooth transition is typically provided between adjacent bevels, between a bevel and an outer surface of the needle, and/or between a bevel and the lumen of the needle.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/090,548 filed Dec. 11, 2014, and of U.S.Provisional Patent Application Ser. No. 62/150,697 filed Apr. 21, 2015,the entireties of which are hereby incorporated herein by reference forall purposes.

TECHNICAL FIELD

The present invention relates generally to the field of hypodermicneedles for medical use, and more particularly to improved tipgeometries for needles such as for example pen needles used withinjection pens for delivery of insulin or other medications.

BACKGROUND

Various forms of hypodermic needles are used for the delivery ofinjectable medications into the body through the skin of a human oranimal patient, for sampling of blood, and for other medical andresearch purposes. Pen needles, for example, are commonly used byhealthcare providers and patients for delivery of medications such asinsulin for diabetes management.

Pen needles typically include a plastic hub with a hollow needleembedded therein. One end of the needle has a sharp tip for injectionthrough the skin of the patient, and the other end is configured toreceive medication delivered by an injection pen. The hub of the penneedle typically includes threaded or snap connections for removableattachment to the injection pen, so that the needle can be removed afteruse and replaced with a new needle for subsequent use of the injectionpen.

The sharp injection point or tip geometry of a hypodermic needle mayaffect its function and/or play a part in user preferences. For example,different tip geometries may require more or less force to penetrate theskin during an injection, and/or different users may perceive differentpain levels or different tactile feedback resulting from injections withneedles having different tip geometries.

SUMMARY

The present invention relates to improved tip geometries for hypodermicneedles or cannulas used, for example, in the delivery of medication, inblood sampling, or in other medical or research applications. In exampleforms, the invention relates to improved tip geometries for pen needlesused in combination with injection pens, such as for example in theadministration of insulin for diabetes management.

In one aspect, the present invention relates to a multi-beveled needletip geometry having a proximal bevel formed at a first angle ofinclination relative to the longitudinal axis of the needle shaft, apair of intermediate bevels formed at a different second angle ofinclination relative to the longitudinal axis, and a pair of distalbevels formed at a third angle of inclination relative to thelongitudinal axis and/or at different angles of rotation relative to thelongitudinal axis of the needle shaft and/or relative to a vertical axisgenerally transverse and orthogonal to the longitudinal axis of theneedle. Preferably, no rotational offset is provided between theproximal bevel and the intermediate bevels, and the substantiallydifferent first and second angles of inclination define a marked apex orpeak at the intersection of the proximal bevel with each of theintermediate bevels.

Optionally, one or more radiused transitions are formed at theintersection of adjacent bevels to provide a smoother transition betweenangular offsets between the bevels, between at least one of the bevelsand the lumen of the needle, and/or between at least one of the bevelsand an outer surface of the needle.

In another aspect, the invention relates to a multi-beveled pen needleincluding a needle shaft or cannula and a multi-beveled point.Preferably, at least one radiused transition is formed between adjacentbevels, between at least one of the bevels and the lumen, and/or betweenat least one of the bevels and an outer surface of the cannula such thata clear transition or intersection forming an edge or discontinuitybetween adjacent surface features is not present.

In still another aspect, the invention relates to a method of forming amulti-beveled pen needle tip including: providing a hollow needle orcannula extending from a proximal end to a distal end along alongitudinal axis, the needle comprising a lumen extending therethroughalong the longitudinal axis; affixing the proximal end of the needlewithin a fixture, the distal end being generally free from engagementtherewith; positioning the needle at a first inclination angle relativeto the longitudinal axis; grinding the distal end to form a proximalbevel; positioning the needle at a second inclination angle relative tothe longitudinal axis; grinding the distal end to form a pair ofintermediate bevels, the intermediate bevels being generally adjacentthe proximal bevel; positioning the needle at a third inclination anglerelative to the longitudinal axis; rotating the needle about thelongitudinal axis to a first rotational angle relative to a verticalaxis, the vertical axis being generally transverse relative to thelongitudinal axis; grinding the distal end to form a first distal bevel;rotating the needle about the longitudinal axis to a second rotationalangle relative to the vertical axis, the second rotational angle beinggenerally opposite the first rotational angle; grinding the distal endto form a second distal bevel; and forming a smooth and radiusedtransition between at least two of the bevels, between at least one ofthe bevels and the lumen, and between at least one of the bevels and anouter surface of the needle.

In yet another aspect, the invention relates to a multi-beveled penneedle including a multi-beveled point and at least one smoothed andradiused transition between adjacent bevels, between at least one of thebevels and the lumen, and/or between at least one of the bevels and anouter surface of the needle. The needle generally extends from aproximal end to a distal end along a longitudinal axis and includes anelongate lumen extending therethrough. The multi-beveled point is formedproximal at least one of the ends of the needle and includes at least aproximal bevel and a pair of distal bevels. The proximal bevel is formedat a first angle of inclination relative to the longitudinal axis andthe pair of distal bevels are formed generally symmetrically at both asecond angle of inclination and corresponding angles of rotationrelative to the longitudinal axis and/or a vertical axis positionedtransverse to the longitudinal axis. The different first and secondangles of inclination result in an apex or peak at bevel intersections,which optionally may be rounded or radiused to provide a smoothertransition between bevels.

These and other aspects, features and advantages of the invention willbe understood with reference to the drawing figures and detaileddescription herein, and will be realized by means of the variouselements and combinations particularly pointed out in the appendedclaims. It is to be understood that both the foregoing generaldescription and the following brief description of the drawings anddetailed description of example embodiments are explanatory of exampleembodiments of the invention, and are not restrictive of the invention,as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a distal-end perspective view of a pen needle according to anexample embodiment of the present invention.

FIG. 2 is a perspective assembly view of the pen needle of FIG. 1 ,shown with the protective caps or covers separated from the needle huband with the sharp tip of the needle exposed.

FIG. 3 is a perspective view of a needle-tip portion of the pen needleof FIG. 1 , showing a needle-tip geometry according to an exampleembodiment of the invention.

FIG. 4 is a detailed view of the needle-tip portion of FIG. 3 , showingsmooth radiused transitions between the bevels, between the bevels andthe interior surface of the lumen, and between the bevels and the outerperiphery of the needle.

FIG. 5 is a further-detail and different-perspective view of theneedle-tip portion of FIG. 3 .

FIG. 6A is a side view of the needle-tip portion of FIG. 3 , showing theinclination angles of the proximal and intermediate bevels.

FIG. 6B is a side perspective view of the needle-tip portion of FIG. 6A,showing the inclination angle of the distal bevels.

FIG. 7 is a partial cross-sectional view of the needle-tip portion ofFIG. 6A taken along line 7-7, showing the angle of rotation of thedistal bevels.

FIG. 8 is a top view of the needle-tip portion of FIG. 3 .

FIG. 9 is a perspective view of a needle tip according to anotherexample embodiment of the present invention.

FIG. 10 is a perspective view of the needle-tip portion of FIG. 9 ,showing smooth radiused transitions between the bevels, between thebevels and the interior surface of the lumen, and between the bevels andthe outer periphery of the needle.

FIG. 11 is a detail view of the needle-tip portion of FIG. 9 .

FIG. 12A is a side view of the needle-tip portion of FIG. 9 , showingthe inclination angle of the proximal bevel.

FIG. 12B is a side perspective view of the needle-tip portion of FIG.12A, showing the inclination angle of the distal bevels.

FIG. 13 is a partial cross-sectional view of the needle-tip portion ofFIG. 12A taken along line 13-13, showing the angle of rotation of thedistal bevels.

FIG. 14 is a top view of the needle-tip portion of FIG. 9 .

FIG. 15A is a distal-end perspective view of a pen needle according toanother example embodiment of the present invention.

FIG. 15B is a perspective assembly view of the pen needle of FIG. 15A,shown with the protective caps or covers separated from the needle huband with the sharp tip of the needle exposed.

FIGS. 16A-16D show top, side, side perspective and end views,respectively, of a needle, for example for use in a pen needle assemblyaccording to FIG. 15A, having a multi-bevel needle tip geometryaccording to a further example embodiment of the invention.

FIGS. 17A and 17B show detailed perspective and top views of a needlehaving a multi-bevel needle tip geometry according to an exampleembodiment of the invention.

FIGS. 18A and 18B show detailed side and top views of a needle having amulti-bevel needle tip geometry according to an example embodiment ofthe invention.

FIGS. 19A and 19B show detailed side and top views of another needlehaving a multi-bevel needle tip geometry according to an exampleembodiment of the invention.

FIG. 20 shows a detailed top view of another needle having a multi-bevelneedle tip geometry according to an example embodiment of the invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The present invention may be understood more readily by reference to thefollowing detailed description of example embodiments in conjunctionwith the accompanying drawing figures, which form a part of thisdisclosure. It is to be understood that this invention is not limited tothe specific devices, methods, conditions, or parameters describedand/or shown herein, and that the terminology used herein is for thepurpose of describing particular embodiments by way of example only andis not intended to be limiting of the claimed invention. Any and allpatents and other publications identified in this specification areincorporated by reference as though fully set forth herein.

Also, as used in the specification including the appended claims, thesingular forms “a,” “an,” and “the” include the plural, and reference toa particular numerical value includes at least that particular value,unless the context clearly dictates otherwise. Ranges may be expressedherein as from “about” one particular value and/or to “about” or“approximately” another particular value. When such a range isexpressed, another embodiment includes from the one particular valueand/or to the other particular value. Similarly, when values areexpressed as approximations, by use of the antecedent “about,” it willbe understood that the particular value forms another embodiment.

With reference now to the drawing figures, wherein like referencenumbers represent corresponding parts throughout the several views, FIG.1 shows a pen needle P in example form. FIG. 2 shows the pen needle P,with its needle guard G and cover C removed from the hub H, to exposethe sharp needle tip N. In some example forms, the needle guard G and/orthe cover C are/is color tinted.

FIGS. 3-8 show a sharp point or tip geometry of a needle 10 according toan example embodiment of the present invention. In example forms, theneedle 10 can comprise the needle N of a pen needle P such as is shownin FIGS. 1 and 2 , the needle of a standard hypodermic syringe, or theneedle of various other devices for injection or other medical orresearch applications. The needle 10 generally comprises a tube orcannula 12 defining a fluid-carrying duct or lumen 14 extendingtherethrough along a longitudinal axis A from a proximal end 16 to adistal end 20. In typical embodiments, both the cannula 12 and the lumen14 (i.e., the inner and outer wall surfaces of the cannula) aregenerally cylindrical in shape and concentrically or coaxiallypositioned relative to each other to generally define a substantiallycontinuous wall thickness along the length of the cannula 12. Theproximal end 16 and/or medial portions of the needle 10 are configuredfor attachment to the hub of a pen needle, to the barrel of a syringeassembly, or to another device or fixture. The distal end 20 preferablycomprises a multi-beveled point 22 including a plurality of beveledfaces, for example as detailed herein. While generally described hereinwith respect to embodiments taking the form of a pen needle tipgeometry, the tip geometry of the present invention may also be adaptedto use in connection with various other items, such as for examplehypodermic needles, lancets, catheters and the like.

The multi-beveled point 22 is generally characterized by an axial lengthL (see FIG. 8 ), and the plurality of beveled faces thereof aregenerally formed around/along a periphery 26 of the lumen 14. Theplurality of bevels may contiguously bound the distal opening of thelumen 14 or may be spaced a distance from the edge of the lumen. In theembodiment of FIGS. 3-8 , the multi-beveled point 22 comprises aproximal bevel 30, a pair of intermediate bevels 32 a, 32 b, and a pairof distal bevels 34 a, 34 b. In the depicted embodiment, the pair ofintermediate bevels 32 a, 32 b and the pair of distal bevels 34 a, 34 bare symmetrically formed relative to the proximal bevel 30, but inalternate embodiments the bevel configuration may be asymmetric.

Optionally, a radiused, rounded, or otherwise smooth transition zone isformed between the bevels (generally axially), between the bevels andthe lumen (generally radially), and/or between the bevels and the outerperiphery of the cannula 12 (generally radially). For example, asdepicted in FIGS. 4 and 5 , a first smooth transition 40 a is providedbetween the distal bevels 34 a, 34 b, meeting together at anlongitudinal apex 36. A second smooth transition 40 b is providedbetween the distal bevel 34 a and the intermediate bevel 32 a, a thirdsmooth transition 40 c is provided between the distal bevel 34 b and theintermediate bevel 32 b, a fourth smooth transition 40 d is providedbetween the intermediate bevel 32α and a portion of the proximal bevel30, and a fifth smooth transition 40 e is provided between theintermediate bevel 32 b and a portion of the proximal bevel 30. Inexample embodiments, a smooth transition 42 is also provided betweeneach of the bevels positioned along the periphery 26 of the lumen 14 andan interior surface 15 of the lumen 14 (e.g., bevel-to-intralumentransition), and a smooth transition 44 is provided between theintersection of each of the bevels and the outer surface or periphery ofthe cannula 12. In example forms, the smooth transitions generallycomprise a radius of curvature R of between about R 0.0001-R 0.035millimeters, for example about R 0.02 millimeters. Preferably, thesmooth transitions avoid a sharp edge or clearly defined intersectionbetween the bevels and other surfaces of the needle tip such thattransitions between the surfaces are smooth. The smooth transitions maybe formed, for example, by bead blasting, grinding, polishing, coatingor otherwise treating the needle surface(s).

FIGS. 6A, 6B and 7 show further details of the multi-bevel point 22. Asdepicted in FIG. 6A, the proximal bevel 30 is formed at a firstinclination angle 30α and the intermediate bevels 32 a, 32 b are formedat a substantially different (i.e., not substantially equal) secondinclination angle 32α, the angles 30α and 32α being defined relative tothe longitudinal axis A of the needle shaft. The proximal andintermediate bevels 30, 32 a-b are preferably formed at the samerotational angle (i.e., with no rotational offset about the longitudinalaxis A). The first inclination angle 30α may be, for example, betweenabout 7.3-7.7 degrees relative to the axis A, and the second inclinationangle 32α may be, for example, between about 9.3-9.7 degrees relative tothe axis A, thus defining an angular offset or difference of about 2degrees (i.e., about 20%-25% relative difference in the angles 30α and32α). In alternate embodiments, the first inclination angle 30α is, forexample between about 6.0-9.0 degrees, and the second inclination angle32α is, for example between about 8.0-11.0 degrees. In still otherembodiments, the first inclination angle 32α is about 8 degrees and thesecond inclination angle 32α is about 10 degrees, resulting in adifference of about 2 degrees (i.e., about 22% different). Preferably,the angular offset or difference between the first inclination angle 30αand the second inclination angle 32α is at least about 1.0-2.0 degreesor more, or at least about a 10%-20% difference or more. Provision ofsubstantially unequal first and second inclination angles 30α and 32α inthis manner results in a marked apex or peak at the intersections of theproximal bevel 30 and the intermediate bevels 32 a, 32 b, in thevicinity of the rounded or smooth transitions 40 d and 40 e.

With reference to FIG. 6B, the distal bevels 34 a, 34 b are formed at athird inclination angle 34α relative to the longitudinal axis A, of forexample between about 18-19 degrees. In alternate embodiments, the thirdinclination angle 34α is between about 17-20 degrees relative to thelongitudinal axis A, or for example between about 22.2-22.3 degrees.Preferably, prior to forming the distal bevels 34 a, 34 b, the penneedle 10 is rotated about the longitudinal axis A in the clockwise andcounterclockwise directions respectively, to form the distal bevels 34a, 34 b at substantially different rotational angles (as well as at aninclination angle as described above) relative to the proximal andintermediate bevels 30, 32 a, 32 b. As depicted in FIG. 7 , the entirerotation of the needle 10 between the first distal bevel 34 a and thesecond distal bevel 34 b (shown as rotation angle 34β) is about 130degrees relative to a vertical axis B. Thus, to form the first distalbevel 34 a, the needle is rotated about the longitudinal axis A in theclockwise direction a rotational angle of about 65 degrees and inclinedat the inclination angle 34α. Similarly, to form the second distal bevel34 b, the needle 10 is rotated about the longitudinal axis A in thecounterclockwise direction (from the 65 degrees clockwise position)about 130 degrees in the counterclockwise direction while remaining atthe inclination angle 34α. Thus, in example forms, the rotational anglefor forming the distal bevels 34 a, 34 b is generally provided byrotating the needle 10 about 65 degrees in both the clockwise andcounterclockwise directions about the longitudinal axis A. Optionally,the rotational angles can be between about 55-75 degrees in theclockwise and counterclockwise directions.

The smooth transitions between the bevels may be configured such that anangle 30β is defined between the vertical axis B and the smoothtransitions 40 d, 40 e, and an angle 32β is provided between thevertical axis B and the smooth transitions 40 b, 40 c. In exampleembodiments, the angle 30β is about 90 degrees and the angle 32β isabout 73 degrees. Preferably, since the angle of rotation between theproximal bevel 30 and the intermediate bevels 32 a, 32 b is exactly (orat least substantially) zero, the angle 30β will generally remain closeto 90 degrees. And, since the needle 10 is rotated in the clockwise andcounterclockwise directions prior to forming the distal bevels 34 a, 34b, the angle 32β will generally be between about 60 degrees to about 80degrees relative to the vertical axis B.

With reference to FIG. 8 , in example embodiments, the overall axiallength L of the multi-beveled surface 22 is between about 1.3-1.45millimeters. In further example embodiments, the length L is betweenabout 1.32-1.42 millimeters. In further example embodiments, the lengthL is between about 1.20-1.60 millimeters. In example embodiments, thelength 30L of the proximal bevel 30 is between about 0.800-0.900millimeters, the length 32L of the intermediate bevels 32 a, 32 b isbetween about 0.200-0.250 millimeters, and the length 34L of the distalbevels 34 a-b is between about 0.320-0.450 millimeters. In furtherexample embodiments, the length 30L of the proximal bevel 30 is betweenabout 0.810-0.880 millimeters, the length 32L of the intermediate bevels32 a, 32 b is between about 0.229-0.236 millimeters, and the length 34Lof the distal bevels 34 a-b is between about 0.360-0.400 millimeters. Infurther example embodiments, the length 30L of the proximal bevel 30 isbetween about 0.600-1.050 millimeters, the length 32L of theintermediate bevels 32 a, 32 b is between about 0.110-0.350 millimeters,and the length 34L of the distal bevels 34 a-b is between about0.200-0.620 millimeters. In example embodiments, the length 30L1 of theproximal bevel 30 (measured between the peak and valley of the proximalbevel 30) is between about 0.350-0.390 millimeters. In further exampleembodiments, the length 30L1 is between about 0.355-0.383 millimeters.In further example embodiments, the length 30L1 is between about0.325-0.400 millimeters. As such, in typical embodiments themulti-beveled point forms an elongated distal opening in communicationwith the lumen, the proximal bevel extends longitudinally from aproximal-most part of the multi-beveled point continuously alongopposing elongated sides of the multi-beveled point, and themulti-beveled point has an overall axial length and the proximal bevelhas an axial length that is at least half the overall axial length ofthe multi-beveled point.

The proximal, intermediate and distal bevels 30, 32 a-b, 34 a-b can alsobe defined by their respective arc lengths 30AL, 32AL, and 34AL, asshown in FIG. 8 . The arc length is generally defined along the interioredges of the bevels, along the periphery 26 of the lumen 14, between thetransitions between adjacent bevels. In one example form, the arc length30AL of the proximal bevel 30 is between about 0.930-1.050 millimeters,the arc length 32AL of the intermediate bevels 32 a-b is between about0.220-0.255 millimeters, and the arc length 34AL of the distal bevels 34a-b is between about 0.175-0.245 millimeters. In another example form,the arc length 30AL of the proximal bevel 30 is between about0.944-1.034 millimeters, the arc length 32AL of the intermediate bevels32 a-b is between about 0.232-0.240 millimeters, and the arc length 34ALof the distal bevels 34 a-b is between about 0.203-0.213 millimeters. Inanother example form, the arc length 30AL of the proximal bevel 30 canbe between about 0.650-1.550 millimeters, the arc length 32AL of theintermediate bevels 32 a-b can be between about 0.150-0.350 millimeters,and the arc length 34AL of the distal bevels 34 a-b can be between about0.100-0.315 millimeters.

The pen needle 10 of the present invention can be formed from a steelmaterial, for example a stainless steel, for example by drawing, moldingor other manufacturing processes. In example forms, the needle 10comprises an outer diameter OD and an inner diameter ID. The outerdiameter OD is measured across the outer peripheral surface of thecannula 12 and the inner diameter ID is measured across the innersurface 15 of the lumen 14. In example forms, the outer diameter OD ofthe needle 10 is generally between about 0.1770-0.3460 millimeters, orfor example from about 29 gauge to about 34 gauge, and the innerdiameter is between about 0.0550-0.2260 millimeters. In further exampleforms, the outer diameter OD is between about 0.1778-0.3430 millimetersand the inner diameter ID is between about 0.0578-0.2230 millimeters. Infurther example forms, the outer diameter OD can be between about0.1700-0.3500 millimeters and the inner diameter ID can be between about0.0500-0.2300 millimeters. In example forms, the pen needle is about4-25 millimeters in overall length. The chart below shows exampledimensions of several gauge needles according to example embodiments ofthe present invention.

Wall Wall OD OD OD Thickness Thickness ID ID Gauge Nominal ToleranceSmall Large Minimum Regular Small Largest 29 0.3366 0.0064 0.3302 0.34300.0600 0.0800 0.1702 0.2230 30 0.3112 0.0064 0.3048 0.3176 0.0600 0.08000.1448 0.1976 31 0.2604 0.0064 0.2540 0.2668 0.0600 0.0800 0.0940 0.146832 0.2350 0.0064 0.2286 0.2414 0.0500 0.0600 0.1086 0.1414 33 0.20960.0064 0.2032 0.2160 0.0500 0.0600 0.0832 0.1160 34 0.1842 0.0064 0.17780.1906 0.0500 0.0600 0.0578 0.0906

In example forms, the needle 10 of the present invention is generallymanufactured in quantity, for example between about 50-1000 needles at atime in an automated process. Typically, an arm or other articulatingstructure comprises a system of fixtures for holding needle blanks, eachof which is ground several times for form the needle tip resulting inthe needle 10. In example forms, the bevels of the multi-beveled tip areground by a disc-like grinding wheel or a belt. In example form, the armholding the fixtures is positioned in close proximity to the grinder toallow for the grinder to provide the multi-beveled face on each of theneedles sequentially or simultaneously. Preferably, the fixture systemprovides for rotation thereof such that the to-be needle can be rotatedto form the distal bevels 34 a-b. Adjustment to the inclination anglemay be provided by angular movement of the arm and/or angular change ofthe inclination angle of each of the fixtures relative to the arm.

In example methods of manufacture, the end of a needle blank may startwith a flat end face prior to being ground. The needle blank is thenpositioned at the inclination angle 30α relative to the longitudinalaxis A and a grinder forms the proximal bevel 30. While remaining at thesame angle of rotation, the inclination angle of the needle blank ischanged to the inclination angle 32α relative to the longitudinal axisA. The grinder then forms the intermediate bevels 32 a, 32 b. Theremaining distal bevels 34 a-b are then formed, which requiresadjustment to the inclination angle and the angle of rotation of theneedle blank. In example form, the needle is adjusted to the inclinationangle 34α and then rotated in the clockwise direction about ½ 34β, forexample from the vertical axis B to the limit of 34β in the clockwisedirection. The grinder then forms the first distal bevel 34 a. Theneedle is then rotated the entire length of the rotation angle 34β inthe counterclockwise direction and the grinder forms the second distalbevel 34 b. Alternatively, the manufacturing process and/or the order ofthe steps to form the bevels can vary.

After the bevels are formed on the tip of the needle 10, the needlepreferably goes through a bead blasting process whereby very small glassbeads are projected onto the multi-beveled point such that any edges,intersections or transitions between bevels and adjacent surfaces areradiused, rounded, or otherwise smoothed. In one form, the projection ofglass beads is not necessarily concentrated on a particular portion ofthe multi-beveled point 22, but instead generally projected at the point22 in a direction generally perpendicular to the longitudinal axis A. Inexample forms, the spray of glass beads is controlled by the equipmentand can be adjusted from a direction generally parallel to the extensionof the needle 10 to a direction generally perpendicular to the extensionof the needle 10 (including any angle therebetween). According to oneexample form, the angle of the spray of the glass beads is configured tobe at about 30 degrees relative to the extension of the needle 10 (e.g.,from being parallel therewith). The needle 10 then goes through analkaline bath, an ultrasonic cleaning process, an acid bath, anelectropolishing process, a cleaning process, and a passivation process.Preferably, these processes ensure that the needle is polished, smooth,free from burrs, and less resistant to corrosion. Optionally, afterprocessing the needle (e.g., electropolishing, cleaning, andpassivation), the needle undergoes a visual or machine inspectionprocess to ensure that quality standards have been met. Generally, theinspection process comprises comparing the needle and its multi-beveledpoint against a sample or image of a satisfactory needle having targetedspecifications. For example, in some example forms, the needle 10 ismeasured and the measurements are compared to a 2-dimensionaldimensioned print of the needle. If the needle is within a specifiedrange or tolerance of the target specifications, the needle passes theinspection and is assembled to form a pen needle, syringe or other item,and further treated and/or packaged for delivery.

FIGS. 9-14 show a pen needle 110 according to another example embodimentof the present invention. The pen needle 110 is in many aspectssubstantially similar to the pen needle 10 as described above, butcomprises a three-bevel tip geometry rather than the five-bevel tipgeometry described above. The pen needle 110 comprises a proximal bevel130 and a pair of distal bevels 134 a, 134 b. Generally, the pen needle110 comprises an elongate cannula 112 having a lumen 114 extendingtherethrough, which extends along a longitudinal axis A from a proximalend 116 to a distal end 120.

A rounded, radiused, or otherwise smooth transition is optionallyprovided between the bevels, between the bevels and the lumen, and/orbetween the bevels and the outer periphery of the cannula 112. Forexample, as depicted in FIGS. 10-11 , a first smooth transition 140 a isprovided between the distal bevels 134 a, 134 b, which meet together ata longitudinal apex 136. A second smooth transition 140 b is providedbetween the distal bevel 134 a and a portion of the proximal bevel 130,and a third smooth transition 140 c is provided between the distal bevel134 b and a portion of the proximal bevel 130. A smooth transition 142is also optionally provided between each of the bevels positioned alongthe periphery 126 of the lumen 114 and an interior surface 115 of thelumen 114 (e.g., bevel to intralumen transition), and a smoothtransition 144 provided between the intersection of each of the bevelsand the outer surface or periphery of the cannula 112.

FIGS. 12A, 12B and 13 show greater details of the multi-bevel point 122.In the depicted embodiment of FIG. 12A, the proximal bevel 130 is formedat a first inclination angle 130α, defined relative to the longitudinalaxis A. For example, in one example embodiment, the first inclinationangle 130α is between about 7.3-7.7 degrees relative to the axis. Inalternate embodiments, the first inclination angle 130α is between about6.0-9.0 degrees. In the depicted embodiment of FIG. 12B, the distalbevels 134 a, 134 b are formed at a second inclination angle 134αrelative to the longitudinal axis A, for example between about 18.0-19.0degrees. In alternate embodiments, the second inclination angle 134α isbetween about 18.3-18.9 degrees. Optionally, the second inclinationangle 134α is between about 17.0-20 degrees relative to the longitudinalaxis A. Preferably, prior to forming the distal bevels 134 a, 134 b, thepen needle 110 is rotated about the longitudinal axis A in both theclockwise and counterclockwise directions respectively, such that thedistal bevels 134 a, 134 b are formed at a substantially differentrotational angle (and at a different inclination angle as describedabove) relative to the proximal bevel 130. As depicted in FIG. 13 , theentire rotation of the needle 110 between the first distal bevel 134 aand the second distal bevel 134 b (shown as rotation angle 134β) isabout 130 degrees relative to a vertical axis B. Thus, to form the firstdistal bevel 134 a, the needle is rotated about the longitudinal axis Ain the clockwise direction about 65 degrees and inclined at theinclination angle 134α. Similarly, to form the second distal bevel 134b, the needle 110 is rotated about the longitudinal axis A in thecounterclockwise direction (from the 65 degrees clockwise position)about 130 degrees in the counterclockwise direction while remaining atthe inclination angle 134α. Thus, in example forms, the rotational anglefor forming the distal bevels 134 a, 134 b is generally provided byrotating the needle 110 about 65 degrees in both the clockwise andcounterclockwise directions about the longitudinal axis A. Optionally,the rotational angle can be between about 55-75 degrees in the clockwiseand counterclockwise directions.

As depicted, the smooth transitions between the bevels may be configuredsuch that an angle 130β is defined between the vertical axis B and thesmooth transitions 140 b, 140 c. In example forms, the angle 130β isabout 73 degrees. Since the needle 110 is rotated in the clockwise andcounterclockwise directions prior to forming the distal bevels 134 a,134 b, the angle 130β will generally be between about 60 degrees toabout 85 degrees relative to the vertical axis B.

As depicted in FIG. 14 , in example embodiments, the length L of themulti-beveled surface 122 is between about 1.30-1.45 millimeters. Infurther example embodiments, the length L is between about 1.32-1.42millimeters. In further embodiments, the length L can be between about1.20-1.60 millimeters. In example embodiments, the length 130L of theproximal bevel 130 is between about 0.800-0.900 millimeters and thelength 134L of the distal bevels 134 a-b is between about 0.320-0.450millimeters. In further example embodiments, the length 130L of theproximal bevel 30 is between about 0.810-0.880 millimeters and thelength 134L of the distal bevels 34 a-b is between about 0.360-0.400millimeters. In further example embodiments, the length 130L of theproximal bevel 130 is between about 0.600-1.050 millimeters and thelength 134L of the distal bevels 134 a-b is between about 0.200-0.620millimeters. In example embodiments, the length 130L1 of the proximalbevel 30 (measured between the peak and valley of the proximal bevel130) is generally between about 0.350-0.390 millimeters. In furtherexample embodiments, the length 130L1 is between about 0.355-0.383millimeters. And in further example embodiments, the length 130L1 isbetween about 0.325-0.400 millimeters.

The proximal and distal bevels 130, 134 a-b can also be defined by theirrespective arc lengths 130AL, 134AL. The arc length is generally definedalong the interior edges of the bevels around the periphery 126 of thelumen 114, between transitions between the bevels. In one example form,the arc length 130AL of the proximal bevel 130 is between about0.930-1.050 millimeters and the arc length 134AL of the distal bevels134 a-b is between about 0.175-0.245 millimeters. In example form, thearc length 130AL of the proximal bevel 130 is between about 0.944-1.034millimeters and the arc length 134AL of the distal bevels 134 a-b isbetween about 0.203-0.213 millimeters. In further example form the arclength 130AL of the proximal bevel 130 is between about 0.650-1.550millimeters and the arc length 134AL of the distal bevels 134 a-b isbetween about 0.100-0.315 millimeters.

In example embodiments, the outer diameter OD of the needle 110 isgenerally between about 0.1770-0.3460 millimeters, or for examplebetween about 29 gauge to about 34 gauge, and the inner diameter isbetween about 0.0550-0.2260 millimeters. In further example embodiments,the outer diameter OD is between about 0.1778-0.3430 millimeters and theinner diameter ID is between about 0.0578-0.2230 millimeters. In stillfurther example embodiments, the outer diameter OD can be between about0.1700-0.3500 millimeters and the inner diameter ID can be between about0.0500-0.2300 millimeters. In example forms, the pen needle is about4-25 millimeters in overall length. The chart above (see paragraph[0047]) shows example dimensions of several gauge needles according toexample embodiments of the present invention.

FIGS. 15A-20 show additional features and embodiments of pen needles andneedle tip geometries according to further example forms of theinvention. In example forms, a pen needle 210 comprises a needle cannula212 attached to a hub 214, a shield 216 and a container or cover 218.The needle 212 has a distal end 220 comprising a multi-beveled point222. The multi-beveled point 222 comprises a plurality of beveled facesincluding a proximal bevel 230, a pair of intermediate bevels 232, oneor more distal bevel(s) 234, and a back bevel 236. In exampleembodiments, the proximal bevel 230, intermediate bevels 232, and distalbevel 234 can be configured substantially similar to the respectivebevels of the embodiments described above. In further exampleembodiments, one or more of the proximal bevel 230, the intermediatebevels 232, and the distal bevel(s) 234 are formed at different anglesof inclination relative to one another and/or at rotational anglesrelative to one another.

The back bevel 236 is preferably formed on the rotationally oppositeside or face of the needle cannula 212 (i.e., at a rotationalorientation of about 180° about the axis C of the cannula) from theproximal bevel 230, intermediate bevels 232, and distal bevel 234. Theback bevel 236 is preferably ground to a depth into the wall thicknessof the cannula 212 sufficient to define a sharp leading edge 240 at thetip of the point 222 where the plane of the back bevel intersects theplane of the distal bevel 234, defining a chisel-tip geometry.Optionally, the back bevel 236 is formed at a slightly angularly offset(from 180°) rotational orientation relative to the distal bevel 234, toform an obliquely angled (relative to the axis C of the cannula) leadingedge 240. In the embodiment depicted in FIG. 16 c , the back bevel isground at a rotational offset of about 152° from the distal bevel 234.In alternate embodiments, the rotational offset can be, for example,within a range of +/−45°, +/−30°, +/−15°, +/−5° and/or other offset fromexactly 180°, to vary the angle of the leading edge 240 relative to theaxis C of the cannula. Or alternatively, the back bevel 236 can beformed at a 180° rotational offset from the distal bevel 234 to form aleading edge perpendicular or transverse to the axis C of the cannula.The needle 210 can be formed in similar fashion as described above, invarious different gauges, lengths, needle formats, etc., as well asvarious different bevel geometries and tip configurations, in exampleembodiments within the scope of the invention.

While the invention has been described with reference to preferred andexample embodiments, it will be understood by those skilled in the artthat a variety of modifications, additions and deletions are within thescope of the invention, as defined by the following claims.

What is claimed is:
 1. A needle, comprising: a cannula having a proximalend, a distal end, a longitudinal axis extending between the proximaland distal ends, an elongate lumen extending axially therethrough alongthe longitudinal axis, and a multi-beveled point at the distal end,wherein the multi-beveled point includes a proximal bevel, a pair ofintermediate bevels, and a pair of distal bevels, the proximal bevelbeing formed at a first angle of inclination relative to thelongitudinal axis, the pair of intermediate bevels being formed at asecond angle of inclination relative to the longitudinal axis, and thepair of distal bevels being formed at a third angle of inclination andhaving angles of rotation relative to a vertical axis which differ fromone another, wherein an angular difference between the first angle ofinclination and the second angle of inclination is at least 20%, theproximal bevel and pair of intermediate bevels having a pair oftransverse edges therebetween, and the pair of intermediate bevels andthe pair of distal bevels having first and second smooth transitionzones therebetween, and the pair of distal bevels having a third smoothtransition zone therebetween; wherein at least one smooth peripheraltransition zone is formed between the proximal bevel, the pair ofintermediate bevels, and the pair of distal bevels and an inner surfaceof the needle defining the lumen, between the proximal bevel, the pairof intermediate bevels, and the pair of distal bevels and an outersurface of the cannula, or both; and wherein the third smooth transitionzone is rounded.
 2. The needle of claim 1, wherein a difference of atleast 1 degree is provided between the first and second angles ofinclination.
 3. The needle of claim 1, wherein a difference of at least2 degrees is provided between the first and second angles ofinclination.
 4. The needle of claim 1, wherein the proximal bevel formsa continuous flat surface.
 5. The needle of claim 4, wherein themulti-beveled point forms an elongated distal opening in communicationwith the lumen, and wherein the proximal bevel extends longitudinallyfrom a proximal-most part of the multi-beveled point continuously alongopposing elongated sides of the multi-beveled point.
 6. The needle ofclaim 5, wherein the multi-beveled point has an overall axial length andthe proximal bevel has an axial length that is at least half the overallaxial length of the multi-beveled point.
 7. The needle of claim 1, incombination with a hub to which the needle is affixed, forming a penneedle for replaceable use with an injector pen.
 8. The pen needle ofclaim 7, in combination with the injector pen.
 9. A needle, comprising:a cannula having a proximal end, a distal end, a longitudinal axisextending between the proximal and distal ends, an elongate lumenextending axially therethrough along the longitudinal axis, and amulti-beveled point at the distal end, wherein the multi-beveled pointincludes a proximal bevel, a pair of intermediate bevels, and a pair ofdistal bevels, the proximal bevel being formed at a first angle ofinclination relative to the longitudinal axis, the pair of intermediatebevels being formed at a second angle of inclination relative to thelongitudinal axis, and the pair of distal bevels being formed at a thirdangle of inclination and having differing angles of rotation relative toa vertical axis, wherein the second angle of inclination issubstantially different from the first angle of inclination to define amarked apex therebetween, wherein a difference of more than 2 degrees isprovided between the first and second angles of inclination, wherein anangular difference of more than 25% is provided between the first andsecond angles of inclination, wherein a respective rounded transversetransition zone is formed between the pair of intermediate bevels andthe pair of distal bevels, and between each of the distal bevels; andwherein the multi-beveled point forms an elongated distal opening incommunication with the lumen, and wherein the proximal bevel forms acontinuous flat surface that extends longitudinally from a proximal-mostpart of the multi-beveled point continuously along opposing elongatedsides of the multi-beveled point.
 10. The needle of claim 9, wherein atleast one smooth peripheral transition zone is formed between theproximal, intermediate, and distal bevels and an inner surface of thecannula defining the lumen, between the proximal, intermediate, anddistal bevels and an outer surface of the cannula, or both.
 11. Theneedle of claim 9, wherein the multi-beveled point has an overall axiallength and the proximal bevel has an axial length that is at least halfthe overall axial length of the multi-beveled point.
 12. The needle ofclaim 9, in combination with a hub to which the needle is affixed toform a pen needle, and in combination with an injector pen for which thepen needle is for replaceable use.